Adam's Norco A-Line 2009 with HS3540

Show off your E-bike creation here.
User avatar
adam333   100 W

100 W
Posts: 270
Joined: Mar 16 2011 3:32pm
Location: Montreal
Contact:

Adam's Norco A-Line 2009 with HS3540

Post by adam333 » Feb 25 2012 7:03pm

I made some modification to upgrade the bike utilities. Initially:
Image

Now I basicaly added a DH kickstand designed to fit an A-Line + the rear mudguard is now acting as a mudguard.
Image

Steering at low speed is a bit odd although I get used to it quickly. As soon as you go above 25kph, the feeling is awesome. Steering is really quick, I would compare it as driving a 400 lbs motorcycle. Pretty stable at high speed and in curves. The weight at the front prevent any chance for me to make wheeling even if I didn't increase my wheel base distance. ( controller is limited at 45 A though )

Data:

Battery pack weight : 23.4 lbs ([100.8V], 24S, 2P, 30C, 16Ah Lipo) [specific energy 130-200 Wh/kg]: http://www.hobbyking.com/hobbyking/stor ... ouse_.html
Bike weight with battery pack : 96.4 lbs
Bike + driver ( me @ 175 lbs ): 271.4 lbs
Max speed according to CA : 88 kph ( 55 mph ) ( Controller is limited at 45 A )
Bike: Norco A Line 2009 Park Edition, Medium frame: http://www.norco.com/archives/2009/?id=48a31c94f3e4f
Motor : Crystalyte HS3540
Controller: Lyen 150V : http://endless-sphere.com/forums/viewto ... 31&t=18605
Schlumpf drive: 34 T front, 14 T rear. High Speed Drive ( 2.5:1 ) Efficient pedaling up to 50 km/h ( 31 mph )http://www.schlumpf.ch/hp/hsd/hsd_engl.htm
Run time : average is roughly 90min @ 35 kph (22 mph). Distance = 50km ( 31 miles )
Charge time : 3hours @ 1/2C ( limited by my power supply ). It will go down to 45min @ 2C once the new charger is built.
Charge cost : 0.20$ / 100km ( 60miles )
Average of 26 WH/km @ 35 kmh (22 mph)
Average of 35 WH/km @ 50 kmh (31 mph)



Now, the development part:

I only made one E-bike before this one, but the experience I got from riding in Montreal's road at 70 kph without suspenison is ... Frightening!!!

So, this time I openned the wallet and bought a DH Norco A-Line Park Edition 2009:

Image

The Motor is a Crystalyte HS3540:

Image

The 2009 A-Line was chosen mainly because of its removable dropouts. The first task was to scan those dropouts on a 3D scanner then rebuild those on the CAD.

My initial goal was to make them stronger around the pivot, as well as the break attachment and add the 7.5mm per dropout to be able to fit the HS3540 in this 150mm frame.

Original dropout:

Image

changes to be made:

Image

Rendered result:


Image

Image

I have a small CNC at home, but those dropout are too big for the machine capacity. The quote to make this set was 1500$ and 520$ from two local machine shop in 6061-T6 ...

Price was just too high so I went with the plan B. (modify and re-use the old drop-out then glue or press fit an insert as Doctorbass did.)

Insert in Dormex 100 or S.S.:

Image

Result pres fit + DP 420 epoxy:

Image

The extra 7.5 mm is included in the insert to fit the 135mm requirement for the HS3540 motor.

Image

Now, from CAD to reality:
Each insert was 85$ and were made from Francois G. I did the modification on the Alu dropout with my CNC and a jig that I designed.
Image

Image

Image

Press fit result:
Image

Assembly part 1:
Image

Assembly part 2 with nut, washer and lock washer:
Image

Assembly part 3:
Image


The wheelbase is then exactly the same (1170mm or 46in). 22 lbs of LiPo battery at the front, 100.8v, 16Ah and the Lyen controller limit the current at 45A. This weight/current set-up prevent the front wheel from lifting.


Front box: I use a Seahorse 520 http://www.seahorse.net/se520.aspx sealed lockable box for the Front battery pack:
They also offer to modify the box cutouts if you send them a 3d drawing.

Image

I made the box holder out of Black Delrin. The box contain 24S2P Zippy LiPo battery. 100,8V 16AH ( roughly 22 lbs ):

Image
Image


The battery is packaged in a 2mm foam layer and is removable by releasing 2 velcro straps ( not shown ).


Key switch + 6 pin connector for charging with protective cap + delrin holder are shown on this view.
Image
The velcro strap anchor are bolted in the Delrin holder with a 1 1/2" bolt:
Image

Completed battery pack ( 24S, 2P, 30C, 16Ah Lipo, 23.4 lbs)
I'm using 2mm foam around all battery.
The battery is removable as an assembly and come with the balance cable as shown below:
Image

Battery strapped with velcro inside the box. Centered and constrained.
Image

Charging area in the garage:
Image

Home made charger with 4 x Turnigy 200W unit. They are connected in serie and each is powered by an isolated individual power supply. This allow me to charge without disconnecting anything.
Image

Not having a stand is annoying, so I made a hanging support to stabilize the bike. It allow me also to remove the front wheel easily as the wheel is 1/4" above ground.
Image

After 935km done on my initial battery pack ( 41 cycles ) charging cost is just below 2$
Image

Of course the CA bracket didnt fit between the stems brackets... so I decided to make a stronger holder.

Material is black Delrin. Mass = 56g
Image
Image
Image
Image

Since the Seahorse box is waterproof and there is limited air flow inside, I was worried about the battery temperature inside the box.
I designed and added a holder + temperature sensor to monitor it while running. ( temperature sensor is inside, near the top of the box )
After several rides under hot and sunny days, the internal temperature never reached 40 deg C.

Image
Image

I also adapted the GPS holder on top of the box:
Bolted from inside the box, (sorry about the muddy picture )
Image

Temp sensor + GPS in place:
Image

I bought a 5 led rear reflector that have a vibration sensor + a light sensor.
This one will activate by himself when its dark outside and stop after 4 min of "no vibration" activity.
Since no useful bracket came with it, I decided to make a decent one custom fit to my rear fender:
Image
Image
Image

A-Line DH Kickstand:

Alu 6061-T6 black painted designed pieces with a modified 10$ kickstand.
Image
Image
Image
Image
Image
Last edited by adam333 on Apr 19 2017 7:40pm, edited 39 times in total.

User avatar
rojitor   100 kW

100 kW
Posts: 1018
Joined: Mar 23 2011 6:39pm
Location: vigo spain

Re: Adam's Norco A-Line 2009 with HS3540

Post by rojitor » Feb 25 2012 8:08pm

Very nice project! Can't wait to see it done.

User avatar
sn0wchyld   1 MW

1 MW
Posts: 1633
Joined: Mar 18 2011 8:27pm
Location: South Aus.

Re: Adam's Norco A-Line 2009 with HS3540

Post by sn0wchyld » Feb 25 2012 9:49pm

Ha! good to see yet another aline in the works! damn I wish I had access/the cad skills for that type of machining...

I'd suggest designing clamping drop-outs via a pinch bolt, as getting a enclosed dropout to fit snugly on these axles is near impossible, given they will loosen up over time. Also it makes removing the rear wheel a simpler and faster process, ie 2 bolts vs 9. I'll be modding mine to be pinch bolts fairly soon...

User avatar
fractal   1 kW

1 kW
Posts: 322
Joined: May 10 2011 1:26pm

Re: Adam's Norco A-Line 2009 with HS3540

Post by fractal » Feb 25 2012 10:10pm

good work! what kind of cnc do you have?
Norco A-line DH bike with :
«cromotor/hubzilla» from http://www.greyborg.com/
24s 3p Lipo (100v, 15ah)
Methods LVC/HVC cell level protection system http://www.methtek.com
24 fet infineon controller made by Lyen, heavily moded by Methods
8awg harness by Icecube57
17 inch moped rims with Michelin Gazelle tires by John Rob Holmes http://www.holmeshobbies.com
other stuff http://www.ebikes.ca

details
http://www.helicamguide.com

User avatar
MattyCiii   100 kW

100 kW
Posts: 1367
Joined: May 05 2007 2:06pm
Location: Boston, MA, USA

Re: Adam's Norco A-Line 2009 with HS3540

Post by MattyCiii » Feb 25 2012 10:19pm

Yeah mighty nice to see another A-Line build in the works. Frankly I bought that 2009 frame, inspired by Oatnet, Sn0wychild and Fractal's builds... Now I have another one to draw inspiration/ideas from.

Love the Magicshine mounted to the Pelican Case. You should mount one on each side, it will give you the appearance of depth. When a car comes hastily to the top of a street and glances left for an opening, two lights look like an oncoming car & might be the difference between them stopping and not.

**subscribed!**
1st build: Dahon Jetstream folding bike. Quick, reliable, capable of 32mph. Light enough to lift, folds for easy transport by car/bus/train.
2nd build: RC powered 2009 Norco A-Line. Top speed 39mph. Built like a tank, it's resistant to Boston potholes, can stop on a dime, easily goes up/down curbs when necessary.
3rd build (just started): Scratch build ultimate utility bike. Based on a common power module using a NuVinci left side freewheel.

User avatar
Brentis   10 kW

10 kW
Posts: 871
Joined: Apr 05 2010 4:25pm
Location: PEI, Canada

Re: Adam's Norco A-Line 2009 with HS3540

Post by Brentis » Feb 25 2012 10:44pm

:shock:
Awesome.
You must be in the business? CNC or Design or something.
You have mad skills.
Canadian too. :wink:

Im going to have to take a ride out East & meet some of you mad men.

I'll do Ottawa, Montreal, then Quebec City trip. Need to see the Doctor.
From here in Barrie, ON.
Sorry YPedal. I'll make it to Moncton someday.
I'm part Newf' & have lots of family still on the Rock.
I've never been, but it's on the bucketlist.
Maybe I'll stop on the way. :wink:


Keep us updated.

:mrgreen:

User avatar
adam333   100 W

100 W
Posts: 270
Joined: Mar 16 2011 3:32pm
Location: Montreal
Contact:

Re: Adam's Norco A-Line 2009 with HS3540

Post by adam333 » Feb 26 2012 6:59pm

Thanks for all the kind words guys.
sn0wchyld wrote:I'd suggest designing clamping drop-outs via a pinch bolt, as getting a enclosed dropout to fit snugly on these axles is near impossible.
I am not sure myself if a clamping drop-out is required with so much meat to hold the shaft, but I agree that the shaft will always move a litle if not clamped.

It could be something like this in order to avoid removing too many screws :
Image

fractal wrote:good work! what kind of cnc do you have?
I have a small EMCO PC mill 50. 170 x 90 mm working area only.
MattyCiii wrote:Love the Magicshine mounted to the Pelican Case. You should mount one on each side, it will give you the appearance of depth
Agreed, I will mount 2 total, I just need to order a new one.
Brentis wrote:You must be in the business? CNC or Design or something.
You have mad skills.
Canadian too. :wink:
Thanks :) I dont have much experience in bike, but I have 15 years experience doing 3D CAD design, and maybe 10 years doing CNC programing/milling/turning.
Last edited by adam333 on Apr 19 2017 7:42pm, edited 1 time in total.

User avatar
MattyCiii   100 kW

100 kW
Posts: 1367
Joined: May 05 2007 2:06pm
Location: Boston, MA, USA

Re: Adam's Norco A-Line 2009 with HS3540

Post by MattyCiii » Feb 26 2012 9:02pm

Really nice CAD work!

Keep the design files. So many people here use triple-crown forks, I'll bet you can make some money on the side machining those Delrin case mounts as a kit for people who want to copy your arrangement. Such attention to detail, this will be a beautiful bike all told.
1st build: Dahon Jetstream folding bike. Quick, reliable, capable of 32mph. Light enough to lift, folds for easy transport by car/bus/train.
2nd build: RC powered 2009 Norco A-Line. Top speed 39mph. Built like a tank, it's resistant to Boston potholes, can stop on a dime, easily goes up/down curbs when necessary.
3rd build (just started): Scratch build ultimate utility bike. Based on a common power module using a NuVinci left side freewheel.

User avatar
rui_fujino   1 kW

1 kW
Posts: 377
Joined: Aug 14 2010 2:10am
Location: UK/Japan

Re: Adam's Norco A-Line 2009 with HS3540

Post by rui_fujino » Feb 26 2012 9:15pm

looking VERY good!! Best of luck! :mrgreen:
Project 1: Apollo slant hard tail MTB 52v lifepo4, conhismotor, 52T-11T gearing 39.6mph top speed (with pedal)
Project 2: Diamondback s:10 Full suspension 20s2p (83.5v 10ah Lipo), 35kg, HS3540 sensored (MethTek), 12FET lyen controller, Bulk 600w balance charger.
Top speed 45mph(72.4km/h)
Project 3: DOPPELGANGER d2 Visceral
Project 5 Specialized Epic20s2p (83.5v 10ah Lipo), 30kg,HS3540 sensored (MethTek), 12FET lyen @ 50A
Top speed 45mph(72.4km/h)
EV miles: 3000miles (2015/06/26)

User avatar
sn0wchyld   1 MW

1 MW
Posts: 1633
Joined: Mar 18 2011 8:27pm
Location: South Aus.

Re: Adam's Norco A-Line 2009 with HS3540

Post by sn0wchyld » Feb 26 2012 9:41pm

adam333 wrote:Thanks for all the kind words guys.
sn0wchyld wrote:I'd suggest designing clamping drop-outs via a pinch bolt, as getting a enclosed dropout to fit snugly on these axles is near impossible.
I am not sure myself if a clamping drop-out is required with so much meat to hold the shaft, but I agree that the shaft will always move a litle if not clamped.

It could be something like this in order to avoid removing too many screws :
Image

......................
Thanks :) I dont have much experience in bike, but I have 15 years experience doing 3D CAD design, and maybe 10 years doing CNC programing/milling/turning.
yep thats pretty much exactly what I have in mind for my own too! just 1 m6-m8 bolt per dropout would probably be plenty too I'd have thought.

User avatar
adam333   100 W

100 W
Posts: 270
Joined: Mar 16 2011 3:32pm
Location: Montreal
Contact:

Re: Adam's Norco A-Line 2009 with HS3540

Post by adam333 » Mar 03 2012 6:43pm

I got the quote... 1500$ for a set if done by the local machine shop in 6061-T6 ... I wish I had a CNC that could machine stainless steel.

I wasnt expecting such a high price for the drop-out. If I order 3 set in 6061-T6, the price go down to 650$ per set.

A cheaper possible solution would be to re-use the old drop-out modified and glue an insert as Doctorbass did.
Last edited by adam333 on Jan 31 2016 8:51pm, edited 1 time in total.

User avatar
MattyCiii   100 kW

100 kW
Posts: 1367
Joined: May 05 2007 2:06pm
Location: Boston, MA, USA

Re: Adam's Norco A-Line 2009 with HS3540

Post by MattyCiii » Mar 03 2012 7:03pm

WOW.
Great to see the alternative... There are a lot of A-Liners out here...
1st build: Dahon Jetstream folding bike. Quick, reliable, capable of 32mph. Light enough to lift, folds for easy transport by car/bus/train.
2nd build: RC powered 2009 Norco A-Line. Top speed 39mph. Built like a tank, it's resistant to Boston potholes, can stop on a dime, easily goes up/down curbs when necessary.
3rd build (just started): Scratch build ultimate utility bike. Based on a common power module using a NuVinci left side freewheel.

User avatar
Andje   10 kW

10 kW
Posts: 746
Joined: Aug 25 2010 11:03am

Re: Adam's Norco A-Line 2009 with HS3540

Post by Andje » Mar 04 2012 1:15pm

How many more A-liner's until we can say "We are Legion"?
Welcome to the fold.
Norco 125 Dirt Jumper
100v 15ah Lipo Backpack
lyens 18 fet, 100v 100 amps, R12 Regen
x5304- 95km/h
http://endless-sphere.com/forums/viewto ... =3&t=24594
Norco A-Line Park 2009
144v Kelly 300amp
5403/ future HS60
http://endless-sphere.com/forums/viewto ... =6&t=35652

User avatar
MadRhino   100 GW

100 GW
Posts: 5969
Joined: Sep 03 2010 5:28pm
Location: Montreal QC Canada

Re: Adam's Norco A-Line 2009 with HS3540

Post by MadRhino » Mar 05 2012 7:14pm

Andje wrote:How many more A-liner's until we can say "We are Legion"?
Welcome to the fold.
He he, not so many more. Norco is almost finished selling this batch of A-line frames. They've been going for cheap because, unlike the previous version, this one didn't do good with the DH - Freeride crowd. I bet Norco will never risk making another A-Line again. The new Aurum and Truax (repacing the Team DH and A-Line) have a completely redesigned suspension frame that is more likely to make a success on the tracks.

Image
Make it fool-proof, and I will make a better fool.
Current bikes
Street: https://s20.postimg.org/ewrvugywt/Session_04_2015.jpg
Dirt: https://s20.postimg.org/lbqwr55ml/IMG_0157.jpg

User avatar
sn0wchyld   1 MW

1 MW
Posts: 1633
Joined: Mar 18 2011 8:27pm
Location: South Aus.

Re: Adam's Norco A-Line 2009 with HS3540

Post by sn0wchyld » Mar 05 2012 7:39pm

MadRhino wrote:
Andje wrote:How many more A-liner's until we can say "We are Legion"?
Welcome to the fold.
He he, not so many more. Norco is almost finished selling this batch of A-line frames. They've been going for cheap because, unlike the previous version, this one didn't do good with the DH - Freeride crowd. I bet Norco will never risk making another A-Line again. The new Aurum and Truax (repacing the Team DH and A-Line) have a completely redesigned suspension frame that is more likely to make a success on the tracks.

Image
'tis a shame, to be sure... maybe they need to go into the ebike business?? :P

User avatar
oatnet   10 MW

10 MW
Posts: 2333
Joined: Apr 26 2007 3:03pm
Location: SoCal, USA

Re: Adam's Norco A-Line 2009 with HS3540

Post by oatnet » Mar 06 2012 6:09pm

Impressive progress Adam, and welcome to the A-Line Army! I really like where you are going with this build, I look forward to watching it unfold. :mrgreen:

Love the front-mount battery box! I put the controller up-front on my wife's bike, but I haven't had the acerage to do it on my other builds; are you sure it won't hit the front wheel when the suspension is compressed? Also, I'd consider super-beefy phase wires for the long run to the motor. BTW, the plastic version of my Magudaman dropouts fit perfectly, but the Ally version didn't give like the plastic did, so you still may see some filing when you get to metal.

-JD
Member 117 of 26,000+

153v DUNE BUGGY © 164v Vectrix E-Moto © 72v Norco A-line/x5403 © 60v Specialized Enduro Comp/BMC © 72v x5tracycle © 48v TF IO/BMC © 36v Kepler FrictionDrive © Spot-Welding a123 © Pelican Front Packs © Vectrix Battery Replacement © MORE !!


Image大鸡巴 Motors
Knowledge is acquired through experience, everything else is just information - Albert Einstein
"Cheater?" I'm not competing, I'm Commuting!

User avatar
adam333   100 W

100 W
Posts: 270
Joined: Mar 16 2011 3:32pm
Location: Montreal
Contact:

Re: Adam's Norco A-Line 2009 with HS3540

Post by adam333 » Mar 06 2012 8:18pm

oatnet wrote:Impressive progress Adam, and welcome to the A-Line Army! I really like where you are going with this build, I look forward to watching it unfold. :mrgreen:

Love the front-mount battery box! I put the controller up-front on my wife's bike, but I haven't had the acerage to do it on my other builds; are you sure it won't hit the front wheel when the suspension is compressed? Also, I'd consider super-beefy phase wires for the long run to the motor. BTW, the plastic version of my Magudaman dropouts fit perfectly, but the Ally version didn't give like the plastic did, so you still may see some filing when you get to metal.

-JD
Thanks Oatnet. Right now, the clearance is 200mm from the wheel to the bottom of the box. Hopefully, this should be enough as I will mainly ride in town's road.

As for the phase wire, I had overheating issues with the previous bike, so I bought 8 AWG 200C wire from KingHobby.

I am fairly confident about the dropout fit as I increased the clearance but we will see. Considering the expensive cost to have the drop out made, I started looking at the possibility to re-use the old one and have some insert made out of S.S. press fit/glued on.

Image
Image

insert S.S.: 85$ ea ( lowest quote so far )
Image

Ideally, I would have Magudaman doing the drop out for me :)

Btw, did you notice any problems so far with your Alu 7075 dropouts?
Last edited by adam333 on Apr 19 2017 7:46pm, edited 2 times in total.

User avatar
oatnet   10 MW

10 MW
Posts: 2333
Joined: Apr 26 2007 3:03pm
Location: SoCal, USA

Re: Adam's Norco A-Line 2009 with HS3540

Post by oatnet » Mar 06 2012 8:42pm

Sadly, since the CroMotor side of the build went belly up, I've been stuck waiting for the xlyte 54xx group buy to arrive, and haven't been able to test the dropouts yet. Your press-fit insert idea is brilliant, never even occurred to me and I pondered the problem long and hard.

-JD
Member 117 of 26,000+

153v DUNE BUGGY © 164v Vectrix E-Moto © 72v Norco A-line/x5403 © 60v Specialized Enduro Comp/BMC © 72v x5tracycle © 48v TF IO/BMC © 36v Kepler FrictionDrive © Spot-Welding a123 © Pelican Front Packs © Vectrix Battery Replacement © MORE !!


Image大鸡巴 Motors
Knowledge is acquired through experience, everything else is just information - Albert Einstein
"Cheater?" I'm not competing, I'm Commuting!

User avatar
adam333   100 W

100 W
Posts: 270
Joined: Mar 16 2011 3:32pm
Location: Montreal
Contact:

Re: Adam's Norco A-Line 2009 with HS3540

Post by adam333 » Mar 08 2012 5:30pm

My best quote on insert is 85 $ ea. Other were charging 175$ and 250$ ea.

If any one is interested to buy some, let me know. I will place an order tomorrow.

User avatar
adrian_sm   10 MW

10 MW
Posts: 2404
Joined: Feb 23 2009 12:54am
Location: Melbourne, Australia
Contact:

Re: Adam's Norco A-Line 2009 with HS3540

Post by adrian_sm » Mar 08 2012 6:00pm

adam333 wrote:I got the quote... 1500$ for a set if done by the local machine shop in 6061-T6 ... I wish I had a CNC that could machine stainless steel.

I wasnt expecting such a high price for the drop-out.
What could you do on your CNC, if you take small cuts? The design is plenty beefy enough that you shouldn't need exotic materials. I would just modify the design so you can do it on your own CNC.

Oh and chuck it through the quick linear FEA in you CAD package if you have access. After a couple of different load cases you should quickly find where you might be able to simplify the design.

- Adrian
Build #1 ~28kg ~ 700w Avanti Hardtail Crystalyte 408, 48V10Ah Headway. ~5500 kms to date. (retired)
Build #2 ~30kg ~2000w Giant AC Dually Crystalyte 408, 48V10Ah Headway + 6s10Ah LiPo = 70V. ~15000 kms to date [SOLD]
Build #3 ~13kg ~2000w Commuter Booster <1kg Friction Drive
Build #??? ~21kg ~1500w Adrian's Bafang BPM Hardtail MTB Bafang BPM code12, 15s LiPo, ~40kph, ~30kms

User avatar
adam333   100 W

100 W
Posts: 270
Joined: Mar 16 2011 3:32pm
Location: Montreal
Contact:

Re: Adam's Norco A-Line 2009 with HS3540

Post by adam333 » Mar 09 2012 12:50am

It take an eternity to work Alu on that CNC, but I will ask a new quote to the same guy that is doing the insert for me. I had to cut a part of the break section to be able to do the plastic prototype. This is why I am not atempting it on my CNC.

Sadly, I dont have FEA available =/
Last edited by adam333 on Mar 09 2012 1:18am, edited 1 time in total.

User avatar
adrian_sm   10 MW

10 MW
Posts: 2404
Joined: Feb 23 2009 12:54am
Location: Melbourne, Australia
Contact:

Re: Adam's Norco A-Line 2009 with HS3540

Post by adrian_sm » Mar 09 2012 12:58am

What a shame. I thought that was the beauty of home CNC, that you can just program it up and let it run, so you don't care how long it takes.

Oh well. In that case chat to the guys doing the quote, and see how you can get some cost out. There might just be a couple of difficult things that is driving the cost.

Good luck.
Build #1 ~28kg ~ 700w Avanti Hardtail Crystalyte 408, 48V10Ah Headway. ~5500 kms to date. (retired)
Build #2 ~30kg ~2000w Giant AC Dually Crystalyte 408, 48V10Ah Headway + 6s10Ah LiPo = 70V. ~15000 kms to date [SOLD]
Build #3 ~13kg ~2000w Commuter Booster <1kg Friction Drive
Build #??? ~21kg ~1500w Adrian's Bafang BPM Hardtail MTB Bafang BPM code12, 15s LiPo, ~40kph, ~30kms

User avatar
adam333   100 W

100 W
Posts: 270
Joined: Mar 16 2011 3:32pm
Location: Montreal
Contact:

Re: Adam's Norco A-Line 2009 with HS3540

Post by adam333 » Mar 19 2012 8:55pm

Last and best price so far for a set of drop-out in 7075-T6 Alu ( not the one with insert ): 520$

User avatar
adam333   100 W

100 W
Posts: 270
Joined: Mar 16 2011 3:32pm
Location: Montreal
Contact:

Re: Adam's Norco A-Line 2009 with HS3540

Post by adam333 » Mar 28 2012 3:58pm

I got my S.S. inserts from Francois Gingras this week. 85$ ea.

Image

Pressed fit result:

Image

Assembly part 1:
Image

Assembly part 2 with nut, washer and lock washer:
Image

Assembly part 3:
Image

I started cabling the controller, 200 deg C 8awg wires for the phases:
Image

Here is the key switch + the access for charging ( there is a protector cap on it ):
Image

Inside the box, design have changed for the bracket ( all images are upside down )
Battery pack will be removable. I will strap it in place with velcro.
Top right is the power supply for the Leds lamp.
Bottom right is the Fuse holder.
I plan to add a temperature sensor too.
Image
Last edited by adam333 on Apr 19 2017 7:53pm, edited 1 time in total.

User avatar
sn0wchyld   1 MW

1 MW
Posts: 1633
Joined: Mar 18 2011 8:27pm
Location: South Aus.

Re: Adam's Norco A-Line 2009 with HS3540

Post by sn0wchyld » Mar 28 2012 5:14pm

adam333 wrote:I got my S.S. inserts from Francois Gingras this week. 85$ ea.

Image

Pressed fit result:

Image

Assembly part 1:
Image

Assembly part 2 with nut, washer and lock washer:
Image

Assembly part 3:
Image

I started cabling the controller, 200 deg C 8awg wires for the phases:
Image

Here is the key switch + the access for charging ( there is a protector cap on it ):
Image

Inside the box, design have changed for the bracket ( all images are upside down )
Battery pack will be removable. I will strap it in place with velcro.
Top right is the power supply for the Leds lamp.
Bottom right is the Fuse holder.
I plan to add a temperature sensor too.
Image

looking really nice mate! can I trouble you for a full bike photo? I'd like to see how subtle the whole thing looks with the front box.
Alternatively I can wait till she's finished!!

Its going to be interesting riding with the same wheelbase... the front box should help but I'm guessing it'll lift the front without too much trouble :twisted: :twisted: !

Post Reply